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April 1, 2006 22 Lit. No. B64090, Rev. 00
ELECTRICAL INSTALLATION – VEHICLE SIDE
1. With the large plug on the electrical harness
placed near the tow hook, under the bumper, route
the harness over the driver-side fender well and to
the fire wall. Insert the connector end of the
harness through an existing hole in the fire wall
and into the vehicle cab. If an access hole does
not exist, drill an appropriately sized hole through
the fire wall in a convenient location away from
sharp edges and hot or moving parts.
NOTE: Keep the plow plug and vehicle connector
pins lubricated with a liberal amount of dielectric
grease. Always replace the protective weather
caps when the plow is disconnected from the
vehicle.
2. Attach the power contactor (solenoid) to the
driver’s side wheel well or engine fan guard using
12-14 x 3/4" self-drilling screws.
NOTE: Some model vehicles provide mounting
locations for accessory components.
Always mount the solenoid with the terminals
facing up, for extended solenoid life. Connect the
24" black ground wire to either small terminal on
the solenoid and attach the opposite end to the
vehicle with a self-drilling screw. Cut the
brown/white pump activation wire on the harness
to length. Strip the end of the harness, and crimp
the eyelet terminal onto it. Attach the eyelet to the
remaining small terminal on the contactor. Secure
it with the hardware provided on the solenoid.
NOTE: Do not fasten the harness to areas that
come in contact with moving engine parts or
possess extreme heat. The harness could become
tangled and/or melt causing electrical failure and
vehicle damage.
3. Connect the vehicle harness ground wire to the
negative terminal on the vehicle’s battery. Cut the
wire to length, and strip the end of the wire. Crimp
and solder a 3/8" ring terminal on the wire.
NOTE: The harness should be secured to the
vehicle prior to taking the necessary
measurement.
Measure the distance needed for the power wire
to reach the solenoid. Strip the wire, then crimp
and solder an end ring terminal to it. Connect the
power wire to either large terminal on the solenoid.
4. Strip both ends of the remaining length of red wire,
then attach and solder an end ring terminal to
both. Connect one end of the wire to the open
terminal on the solenoid and the remaining end to
the positive terminal on the battery.
5. Position the main lighting harness with both of the
truck light connectors near each truck headlight
and the plow light connectors near the grille of the
vehicle.
6. Plug the headlight ground/relay connector from
the vehicle harness into the connector on the main
lighting harness. Securely mount the relay
receptacles to the vehicle with the terminal wires
facing down and the relays facing up. Installing
the relays in this position will allow moisture to
drain from the relay.
Large
Terminals
Small
Terminals
(HD Solenoid Shown)
CAUTION
Before drilling any holes, check the selected
area for wires, hoses or other obstructions.